Gambaran Umum

Common Rail System

Front
Lokasi Part
Engine

Fuel pipe to Injector

injector

Fuel pipe to Rail

Rail
• Pressure sensor
Supply pump • Pressure limiter
•SCV
•Fuel temperature
1
 Fuel System
Diagram Konstruksi Supply Pump

2
 Fuel System

Konstruksi Supply Pump SCV

Plunger

Pump body Feed pump

Fuel temperature sensor

Ring cam

Regulating valve

Drive
shaft Filter

Plunger

3
 Fuel System
Fuel flow dalam supply pump

The fuel that is draw from the fuel tank passes through the
route in the supply pump as illustrated, and is fed into the rail

4
 Fuel System
Fuel pump (DENSO type HP3)

The eccentric camshaft is attached to the camshaft. The

eccentric cam is connected to the ring cam
camshaft

Plunger A

Ring cam

Eccentric Cam Ring cam

Feed pump

The plunger and the suction valve are

attached to the ring cam. The feed pump is
connected to the rear of the come shaft Plunger B

5
 Fuel System
Konstruksi

Plunger

Eccentric Cam

Ring cam

camshaft

6
 Fuel System

Operation

Movie
 Fuel System
Konstruksi Feed Pump

The trochoid type feed pump, which is integrated in the supply pump, draws
fuel from the fuel tank and feeds it to the driven by the drive shaft

Quantity
decrease Quantity decrease (fuel discharge
Outer rotor

Inner rotor

Intake port
Discharge Quantity Quantity increase (Fuel intake)
port increase

8
 Fuel System
Suction Control
Valve

9
 Fuel System
In case of short time ON duty Feed pump

Plunger Maximum intake quantity

Large valve
Short time Large valve open
ON duty opening
Movie 10
 Fuel System
In case of long time ON duty Feed pump

Plunger
Minimum intake quantity

Small valve
Long time Small valve opening
ON duty opening
11
 Fuel System
Injector Structure and System

An injector consists of a nozzle, command piston,

command chamber, and solenoid valve that controls
the ON/OFF of the outflow orifice. The command
piston moves vertically in accordance with the fuel
pressure in the command chamber. As the nozzle is
integrated with the command piston, the orifice of the
injector opens and closes with the vertical movement
of the command piston.

Movie

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 Fuel System
Injector Structure and System

Movie
13
 Fuel System
Injector OFF ON
Operation
Hydraulic
Electro magnetic pressure
Hydraulic valve
pressure

Spring force Spring force

20 to 180MPa 20 to 180MPa

Orifice

Orifice

Nozzle
Movie
Fuel injection 14
 Fuel System
Fuel injection control
1. Fuel injection amount control

Basically, the fuel injection amount is calculated in accordance with

the accelerator position and the engine speed.

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 Fuel System
Fuel injection control
2. Fuel injection timing control

Basically, the fuel injection timing is calculated in accordance with

the engine speed and the target injection amount.
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 Fuel System
Fuel injection control
2. Fuel injection timing control
Engine-ECU injects fuel before and
Multiple stage injection control
after the main injection to suit the
driving conditions. The injection
that takes place before the main
injection is called pre-injection,
which is provided primarily for
reducing combustion noise and NOx.
The injection that takes place after
the main injection is called
after-injection, which is provided
primarily for activating the catalyst.

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 Fuel System
Fuel injection control
2. Fuel injection timing control
EX.) Multiple stage injection control for 4M41 DID

Pre Injection
Main Post
Opening of Injection face

Injection Injection
Pilot After
Injection Injection

Time

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 Fuel System
Fuel injection control
3. Fuel pressure control
System Configuration Diagram

Engine-ECU maintains a high fuel pressure by controlling the rail pressure

in accordance with the signals input from various sensors. Accordingly,
the injection of fuel at a high pressure improves combustion and reduces
the amount of discharge of the particulate matter.

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 Fuel System
Fuel injection control
4. Idle speed control
System Configuration Diagram

Engine-ECU compares the target idle speed with the actual idle speed,
and controls the fuel injection amount so that the actual idle speed will
attain the target idle speed (feedback control).
Furthermore, the following compensations are added to control the engine
at a stable idle speed.
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 Fuel System
Fuel injection control
5. Throttle valve control
System Configuration Diagram

When engine is Engine-ECU actuates the throttle valve control servo to fully open the throttle
running valve. In a driving range in which the exhaust gas recirculation control is being
effected, the throttle valve closes to create a vacuum in the inlet manifold.
When engine is Engine-ECU actuates the throttle valve control servo to fully close the throttle
stopped valve for 3 seconds. This cuts off the flow of intake air and prevents the engine
from run on (dieseling).
When a problem If the engine-ECU detects a serious problem, it immediately closes the throttle
develops valve fully to stop the engine.
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 Fuel System
Sensor

Crank angle sensor Cam position sensor

(56 teeth) (5 teeth)

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 Fuel System
Fuel filter

High cleaning
efficiency filter

23
 Fuel System
Fuel tank

􀁺Mounted on the front of the rear axle to reduce the shock during impact
􀁺Materials without lead and hexavalent chromium have been employed for the fuel
tank with attention to environmental issues.
􀁺A fuel cut valve, which prevents fuel leakage when the vehicle banks or rolls over,
has been located inside the fuel tank for fewer openings and hose bonding points24
on the fuel tank top surface.
 Fuel System
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (S,Q.L.) at the
end of line (E.O.L) check S.Q.L start and S.G.L end by MIL status as follow.
Procedure for Small quantity learning When injector is changed or
Precondition correction has to be applied
1. Vehicle speed : 0km/h to ECU for all cylinder before
automatic learning mode
2. Accelerator pedal: Fully close
3. Power steering : not operated
4. Electric load : Off S.Q.L
5. Water temp. : 80 deg. or higher S.Q.L start complete
Idling 6. AT oil temp. : 60 deg.or higher
7. Oil temperature: 30 deg. or higher MIL: Blink MIL: Off
8. Shift position: N or P
9. A/C : Off
10. Idle condition: stable S.Q.L NG

After I/G Off to ON

When injector is
changed 25
 Fuel System
Common rail engine learning function

After fuel-related parts are replaced, the common rail engine must register their
identification codes with the engine-ECU and execute learning.

Registration and learning item Operation type

Injector Supply pump Engine-ECU
replacement replacement replacement
1 Injector identification Applicable --- Applicable

2 Small injection quantity Applicable --- Applicable

learning (SQL)
3 Supply pump correction --- Applicable ---
learning

Note : When the engine-ECU is replaced, collect in advance the injector

identification code from the current engine-ECU. Doing it makes registration easy.

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 Fuel System
1. Common rail relative parts supply unit
Supply unit Components caution After replacement

Common rail Fuel pressure sensor Replace common rail

Ass’y Fuel pressure limiter ass’y when changing ---------------------
Common rail parts

Supply pump Suction control valve Replace supply pump Initialize learned value
Ass’y Fuel temperature sensor ass’y when changing by MUT-III
Supply pump parts

Injector Pay attention to the Register after erasing

--------------------- discharge because of correction value by
injector drive voltage MUT-III
85V
Engine-ECU Register the injector
---------------------- --------------------- correction value, supply
pump learned value by
MUT-III

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 Fuel System
2. Caution and method of Injector correction(1/2)
1) There are correction value, QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector

Register the this hexadecimal numeral by using key board or touch

panel of MUT-III to engine-ECU

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 Fuel System
2. Caution and method of Injector correction(2/2)
2) Make sure the replace injector cylinder No.
(because it can not detect cylinder No. mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is no/partial value registered in ECU)

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 Fuel System
3. Diagnosis function
Increase diagnosis items (CDI: Approx.100 items , IDI:Approx.30items)
Ex) New diagnosis items
Diagnosis items Diagnosis Failure parts Remarks
code

Abnormal of intake P0638 ETV Failure of ETV motor (judge of valve

valve seized seized)

Abnormal of DC P2118 ETV Failure of ETV motor (excessive

motor excessive current)
current flow
Failure of NE/G P0016 Crank angle Cam position sensor and crank angle
phase unmatched sensor sensor output waveform unmatched
Cam position
sensor
Injector function P0301 to ECU Poor increasing angular speed by
(non injection) P0304 combustion

Fuel leakage P0093 Fuel pipe Suction control valve duty amount
too big against requirement 30
 Fuel System
Common rail engine learning function
1. Injector identification code registration procedure

Purpose : Because individual injectors have different injection characteristics,

the engine-ECU corrects injection time for each cylinder to improve injection
accuracy. For this reason, when the injector or engine-ECU is replaced, injector
correction data must be registered afterwards in the engine-ECU using the MUT-III.
Correction data is converted into an identification code consisting of 30 alphanumeric
characters and printed on the injector connector.

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 Fuel System
Common rail engine learning function
1. Injector identification code registration procedure

Select the write mode from the menu, enter the identification
Code printed on the injector, and execute writing.

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 Fuel System
Common rail engine learning function
1. Injector identification code registration procedure

A. Injector ID code writing (Exchanging engine-ECU)

1) Before replace the current engine-ECU,

connect the MUT-III.
2) Select “Special Function” from the function
menu of MUT-III.
3) Select “INJ. ID Writing (Exchanging ECU)”
menu.
4) Select “Injector ID Read & Save” menu.
Caution
If the injector ID code is not registered, the
engine warning lamp goes on and diagnosis
code No. P1626 is logged.

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 Fuel System
Common rail engine learning function
1. Injector identification code registration procedure

A. Injector ID code writing (Exchanging engine-ECU)

5) The injector ID code from the current engine

-ECU is displayed.
6) Click the Check from task bar.
7) The injector ID code is saved to MUT-III from
the current engine-ECU.
8) Replace the new engine-ECU.

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 Fuel System
Common rail engine learning function
1. Injector identification code registration procedure

A. Injector ID code writing (Exchanging engine-ECU)

9) Select “Saved Injector ID Writing” menu.

10) Select the injector ID code from the current
engine-ECU, click the Check from task bar.
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU.

35
 Fuel System
Common rail engine learning function
1. Injector identification code registration procedure

A. Injector ID code writing (Exchanging engine-ECU)

12) For other way, select “All Injector ID

Writing” menu.
13) Input the each injection ID code by
keyboard.
14) Make sure that the engine warning lamp that
is on changes to blinking, indicating the
registration is complete.
15) Execute small injection quantity learning.

Small Injection Quantity Learning Procedure

36
 Fuel System
Common rail engine learning function
1. Injector identification code registration procedure

B. Injector ID code writing (Exchanging injector)

1) Select “Special Function” from the function

menu of MUT-III.
2) Select “INJ. ID Writing (Exchanging INJ)”
menu.
3) Select number of replaced Injector ID writing
menu or “All Injector ID Writing” menu.
4) Input the each injection ID code by keyboard.

37
 Fuel System
Common rail engine learning function

2. Small Injection Quantity Learning procedure

Purpose : To keep emission and noise level at adequate levels, the engine-ECU
must learn Injector fuel injection in idle mode.
During learning, the engine-ECU calculates actual injection from each cylinder
based on changes in engine speeds and corrects pilot injection control. It then
keeps records of this amount of correction as a learned value.
For this reason, after the engine-ECU or injector is replaced, learning must be
executed using the MUT-III.

Caution
If small injection quantity learning has not been executed,
the engine warning lamp blinks.

38
 Fuel System
Common rail engine learning function
2. Small injector quantity learning procedure
- Engine coolant temperature : 80 – 90ºC
- AT temperature : 60ºC or higher
- Lamps, A/C condenser fan and accessories : OFF
- Transmission : Neutral
- Power steering : Static state

1) Put the vehicle in the left-hand idling stable

condition.
2) Select “Special Function” from the function
menu.
3) Select “Learning” menu.

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 Fuel System
Common rail engine learning function
2. Small injector quantity learning procedure

4) Select “Small Injection qt. Learning” item.

5) Click the Check from task bar.
Caution
If the vehicle conditions go out of the learning
conditions during idling, learning is interrupted.
To re-execute learning, the ignition switch must
Once be turned off.

6) Continue idling for about 3 minutes before

learning is completed.
7) Confirm that the engine warning lamp is
off. If it still blinks, re-execute learning.

40
 Fuel System
Common rail engine learning function
3. Supply Pump Correction Learning procedure
Purpose : To engine-ECU learns the relation between the suction control valve (linear
Solenoid valve) of the supply pump drive current and the fuel injection volume.
The learning value is calculated from the suction control valve drive current and the rail
pressure sensor output voltage.
When the supply pump is replaced, therefore, this learning must be executed.
Re-learning is executed when the engine is idling after the learning value in the engine-ECU
Has been reset by the MUT-III.

Suction Control Valve (SCV)

41
 Fuel System
Common rail engine learning function
3. Supply Pump Correction Learning procedure

- Accelerator pedal : OFF

- Engine coolant temperature : 60ºC or higher
- Fuel temperature : 30ºC or higher

1) Select “Initialization” from the function

menu.
2) Select item No. 21 “Supply pump exchange
service”.

42
 Fuel System
Common rail engine learning function
3. Supply Pump Correction Learning procedure

3) Click the Check.

4) After initializing, run the engine at idle in the
left-hand conditions.
5) Confirm that the item No.65 High pressure
pump learned status on MUT-III Service Data
is “2”.
“FF” : Initial Condition
“0” : Non-learning statue
“1” : Temporary learning completed statue
“2” : Learning Completed statue

43
 Service Detail
Initialization setting value for Supply pump.

supply pump EEPROM

discharge characteristic
data

Initialization setting
value

Replace New data of Supply Pump

Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
44
 Service Detail
Bagaimana mengganti Common Rail ? Common Rail tidak dapat
dibongkar menjadi komponen yang terpisah ( harus diganti secara
assy )

Tidak dapat
Pressure Sensor
dibongkar !
Pressure
Limiter

45
 Service Detail
Bagaimana cara memasukan QR code untuk injector
baru.Saat mengganti Injector atau ECU , harus memasukan
kembali QR Code dari Injector .
ganti Injector QR code baru
New data

Engine ECU
Re - Input
ganti ECU

semua 4 Injectors

46
 Service Detail
Bagaimana memasukan QR code pada Injector
Saat mengganti ECU
Saat mengganti Injector
Save data to MUT –3 Tester
mengganti Injector
Data saving

Input new data

ECU Replacement

Input QR Setting Input saved data

code
Saved data

Delete Code DTC P0201

Delete Code DTC P0604
Register Completed
Register Completed 47
Small injection Quantity Learning
Procedure
PRASYARAT :
- Engine coolant temperature : 80ºC atau lebih tinggi
- AT temperature : 60ºC atau lebih tinggi
- Lamps, A/C condenser fan and accessories : OFF
- Transmission : Neutral
- Power steering : tidak dioperasikan

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50
51
52
53
54
55
56
57
58
59
60
 Injector ID
Procedure

Penggantian Injector

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62
63
64
65
66
67
68
 Injector ID
Procedure

Penggantian ECU

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71
72
73
74
75
76
77
 Supply Pump Initialization
Procedure

PRASYARAT :
- Engine coolant temperature : 60ºC atau lebih tinggi
- Fuel temperature : 30ºC atau lebih tinggi
- Accelerator pedal : OFF

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79
80
81
82
83
 Service Detail
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector Injector Seal

O-Ring
Washer Cylinder head cover

Gasket

O-Ring

Fuel return pipe

Supply pump
84
 Service Detail
Mengganti Rail baru
Mengganti pipa baru saat part-part berikut diganti Discharge
pipe

Part-part Mengganti
yang diganti pipa baru
*Injector Discharge
•*Rail pipe
•*Supply
pump Inlet pipe
•*Rail

Inlet pipe
85
COMMON RAIL SYSTEMS

86
 Service Detail
Procedure for fuel line replacement should be operated with attention to the cautionary statement.
The contents of “CAUTION” is the same as L200 4D56’s. (see below)

87
 Service Detail
Memeriksa kebocoran (Fuel System)
1. IG switch OFF
No leakage

2. Engine Start
No leakage

3. Ganti pipa pengembalian dan start Engine (tidak bisa hidup)

No leakage ( From return pipe)

4. Gunakan MUT-III memeriksa kebocoran dengan actuator test

No leakage
Normal Fuel System
88
 Service Detail
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine

Active Test
•Injector Cut #1
•Injector Cut #2 High voltage
•Injector Cut #3
•Injector Cut #4

Jangan melepas connector injector

89
 Service Detail
Penggantian Fuel Filter Hand pump
Fuel filter
Warning switch
To supply pump

From Fuel tank

Fuel filter case (Aluminum) Filter

Filter

Water level
warning switch

90
 Service Detail
Fuel Filter Structure

Hand pump Fuel filter

Warning switch

From Fuel Tank To Supply pump

Filter Fuel filter case

(Aluminum)

Water level
warning switch
91
 Service Detail
Fuel Filter Warning Lamp Tersumbatnya Fuel filter akan dideteksi
dengan Fuel filter warning switch
Fuel filter warning
switch Fuel Filter
warning lamp

tersumbat

Combination meter.
Saat Fuel filter terdapat beberapa masalah maka Fuel warning lamp
Fuel Filter akan menyala

92
 Service Detail
Fuel Filter Warning Lamp Diagram

Combination meter

Engine Speed sensor

Fuel filter warning
switch
ECU
Combination Fuel Filter warning
meter lamp

To Supply pump
Filter

Filter Water level warning switch

93
 Service Detail
Fuel Filter Warning Lamp
Status Fuel Filter / Water level warning lamp .

Warning Status Step

Water level
warning 1
Flashing

Fuel Filter
warning 2
Showing
94
 Service Detail
Fuel Filter Warning Lamp Diagram
Ketika Fuel filter warning lamp menyala, berarti perlu untuk mengganti filter dan reset warning
lamp

Mengganti filter

Buka Fuel tank

cap.

95
 Service Detail
Fuel Filter Warning Lamp Diagram
Melepas Filter
lepas Inlet hose
lepas Outlet hose Fuel level

lepas Connector

Drain plug
Drain water

96
 Service Detail
Fuel Filter Warning Lamp Diagram

Memasang kembali Fuel filter

Install the fuel tank cap.

Install Inlet and Outlet hose.

97
 Service Detail
Fuel Filter Warning Lamp Diagram
Install fuel filter / Reset warning lamp

Reset warning lamp

Within
3 – 60 sec. 3 sec.

IG ON
OFF

Connect the connector

98
 Service Detail
Fuel Filter Warning Lamp Diagram

Install fuel filter /Reset warning lamp

Keluarkan udara dari Fuel system.

Hand pump

Finish

99